Hernan Escarria. PTI – Santiago de Chile, Junio 2013 Small ... · © ABB Group June 3, 2013 |...

© ABB GroupJune 3, 2013 | Slide 1

Small Power TransformersOverview and developments

Hernan Escarria. PTI – Santiago de Chile, Junio 2013


ABB Transformers – Product GroupSPT

Table of Contents


ABB Transformers – Product Group SPTTable of Contents

Transformers IntroductionSPT – How we are

The ABB approach to SPT manufacturing:Benefits

Short circuit

Innovative Technology solutions:HTC Transformer – Vegetable Oil

PPTR Portfolio

Our experience in the Chilean market



Transformers Introduction


Our every day necessities…Introduction

Areas of powerconsumption reflectedon the earth’s surface

More than ever, the need of energy efficientproducts and reliable grids. ABB’s transformerssupport the systems that keep our world running

Ever growing populationEnergy consumption todouble within 30 yearsSustaining a power-hungry worldConcern about climatechangeEnsuring a reliable gridProviding energy efficientproducts and solutionsInvesting in the future


USA – South Boston

Columbia - Pereira

Italy Monselice

Vietnam - Hanoi

China– Zhongshan &Daton

Finland – VaasaSpecials Vadodara– India

Small Power Transformers – Factories

USA – Cristal Springs

Switzerland - Geneva



The ABB approach to SPTmanufacturing


Small Power TransformersConcepts

Product ExcellenceBased on a Global

Product Platform

Process ExcellenceBased on a the most

advanced production

ABB is unique on the market –

dedicated technology

and production line


Power rating

Sound Cooling

Voltage rating

Mechanical Integrity& Requirements

ImpedanceLoss evaluation

Regulation Insulationlevels

Tests

Specific

Transport

limitation acceleration

Seismicloads

Full ScaleSCC test

Overloads

Accssories, bushings,TC, oil vaves andcorrosive protection

Fixed losses Capitalized

Low noise level

Major cost drivers:Loss evaluationNoiseMecanical requirements

Temp.Gradient,

Ambient temperature

Mech. Integrity

due to SC forces

Small Power TransformersMajor design parameters


Automation

Customization

Reliability

Configurable layoutbased on customerrequirements

Higher quality inshorter time

SC testsin entirerange

Provendesign

No test failures in 18 months

Reduced CoPQ

Reduced TTPT

Proven Conceptbased on ABB common

Design rules , MP, Q-cards Design

robustness

and process

simplification

Process simplification

Small Power TransformersGlobal Product Platform


Product quality: Guaranteed product quality fulfilling requirementsCommon technical standard for all factories (design, method provision, quality

card) Modularization:verified designs

ABB Common Verification tools included in our design tools:Wintran, ACE Trace, Earthquake

Proven short circuit testCommon design toolsThe most advanced production process - AutomationThe highest ratio test per design - Global feedback system

Technology: Most advanced products and solutions available for ourcustomers

Developments shared on global basisSpeed:

Shorter delivery time - On Time DeliveryModularizationHigh throughput production linesAvailability of material

SPT Global Product PlatformBenefits


Local production with global experienceGlobal platform – Global cumulated experience – Local productionEngineers training programTechnology lead centersProduction capacity always available

Global sourcing for global customersPossibility for back up

From all factories same quality standardService quality

Fast and quality documentationGlobal IT platformExcellence in engineering

Service: lower meantime between repair

Modularization facilitates availability of material

Service numbers … 24H numbers in …

SPT Global Product PlatformBenefits


SC tests introduced 1950 -1960

SC tests have been used in different countries

Still Customers didn’t get SC safe transformers

IEC and ANSI has edited Standards

Short circuit test is special test

IEC gives two options to verify the ability to withstandthe dynamic effects of a Short Circuit, IEC 60076 – 5:(2006-2)

by full SC test at a certified lab, or

by theoretical evaluation of the ability to withstand aSC event by manufacturer’s experiences supportedby IEC guidelines.

Short Circuit IntegrityWhy we need it today

His

tory


Networks are today more loaded, newin-feeds as windpower are addedLoad flows are changingNetwork components are ageingThe network operation conditionshave changedNew transformers will see moresevere SC duty than before.

Short Circuit IntegrityWhy we need it today

Tran

sfor

mer

Ope

ratin

g

Con

ditio

ns


•Network disturbances must not give rise toconsequential damages in transformers

Transformers have to withstand mechanicalforce with hundred of tons ( msec)

Temperature rise (sec)

Short Circuit IntegrityIt is a key for operation


The Transformer industry has agreed to make routine andtype tests (IEC and ANSI) to check the integrity on

Electrical insulationLossesTemperaturesAll transformers are high voltage testedSome very few are SC tested

Customers shall consider in tender documentations toinclude new IEC 60076 -5

Short Circuit IntegrityShort Circuit Withstand Capability


Short Circuit IntegrityIt is a key for reliable operation


0

4

8

12

16

20

25-50 50-100 100-200 >200

MVA (rated)

num

bero

ftra

nsfo

rmer

s initially not OK

initially OK

0

4

8

12

16

20-100 100-200 200-300 300-400 >400

kV (rated)

num

bero

ftra

nsfo

rmer

s

initially not OK

initially OK

KEMA numbers published atCIGRE 2006 : 40 % of SPT

transformers ( 25 -50 MVA) failto pass initially short-circuit tests.

Short Circuit IntegrityIt is a key for reliable operation

ABB has 100% success


ABB has done the most number of tests during the yearsand have got a large amount of feedback and experience

ABB Technical Standard is based on the “best practices”

This Standard is adopted worldwide in the ABB PowerTransformer concept

The Standard is continuously improved as a result ofnew findings

ABB has stringent manufacturing control on winding andactive part assembling related dimensions and processes.

ABB has the most advanced manufacturing and SC testsexperience

The SPT concept has been proven by 16 full scale testssince 2004

No other manufacturer has such an extensive test record

Short Circuit Withstand Capability



Innovative Technology solutions


EXPLOSIONS & FIRES


Vegetable OilHigher fire resistance

Listed as “less flammable” dielectric insulating fluidby Factory Mutual (FM Global) and UnderwritersLaboratories (UL)


The great ability of the Biotemp to hold moisture gives theBiotemp much higher water saturation limit than that of mineraloil.

Under normal operating conditions, the water saturation limitof Biotemp is 5 to 8 times greater than that of mineral oil

This signify that in systems including Biotemp and paperinsulation, the paper will hold less water than in insulatingsystems of mineral oil and paper, thus increasing the lifeexpectancy of the insulation paper, as well as the transformer.

Vegetable OilLife expectancy/overload capacity benefits


Vegetable OilEnvironmental benefits

Listed asbiodegradable andnon-toxic insulationdielectric fluid by theUS FederalEnvironmentalProtection Agency(EPA)


HTC transformers can be grouped in three categories :

Mineral oil after 1 minute. Mineral oil after 3 minutes. Mineral oil fully alight after 4 minutes.Note the dense black smoke.

MIDEL 7131 after 3 minutes. MIDEL 7131 after 70 minutes. MIDEL 7131 at 324°C finally ignites.Still no ignition. Note very limited emission of smoke

compared to mineral oil.

Nomex insulation

Transformer with hybrid insulation: solid insulation ( high temperature class pluscellulose paper ) and mineral oil;

High-temperature homogeneous insulation system (full high temperature classtransformer);

Transformer filled with high temperature class liquid ( midel , silicon, bio-term).

High Temperature Class Transformers


ScopeFull or hybrid high temperature class transformers using high classinsulations.Increase market applications (railways application, wind farm, mobilesubstations, etc.) decreasing size and weight. Increase transformer lifeincreasing the insulation class.Develop high temperature class transformers (application for cityinstallation) as some customers (Endesa, Russian Utilities) ask for technicalsolution for high fire risk areas.

ObjectiveStudy the thermal, electrical and mechanical properties of a high viscosityfluids as Midel, Silicon, Bio-term, FR3.Find the better electrical designs for the best cooling performances fortransformers up to 170 kV. Decrease fire and explosion risks in specialenvironments.

TechnologyHigh temperature class paper / epoxy resin instead traditional windinginsulation. Midel instead of mineral oil. It has better electrical and thermalproperties than Silicone Oil.

High Temperature Class Transformers


High Temperature Class TransformersNew Standards

IEEE C.57.154-2012 e IEC 60076-14-2009


ABB TransformersPortfolio

SystemkV

MVA

275

63 20040

172(for SP 1-5 max

BIL 650 kV )

3 PhaseTop Rating

MPT<=200 MVA

172 - 275 kV or BIL >650 kV

MPT>63– 200 MVA>72.5 - 171 kV

LPT> 275 kV

LPT> 200 MVA

>72.5 - 275 kV

SPT10 – 63 MVAUp to 171 kV

72.5

10

0

MDT=0.316- 10 MVA

<=36 kV

SDT<0.315 MVA<=36 kV


Small PowerTransformers

Ground mounted, Pad mounted,Primary unit Substation,Autotransformers for Network,Mobile Substation, single phasenetwork and generator Step Up.

SpecialsRailway (Booster, Railtrack,autotransformers), Furnace andRectifiers, Variable Speed Drives,Marine Applications, Windmillsand reactors.

Rolling Stock

IEC & ANSI and any local standards

Small Power TransformersProduct Tree

Traction transformers

Locomotive , EMU


Que es un sistema de accionamiento electrico (Drive)?

Un sistema de tracción o accionamiento se utiliza para el control de velocidad,par y potencia de un motor eléctrico de la manera más eficiente.

Se compone de transformador, variador de velocidad y el motor

Los principales componentes deben tener características coincidentes

Topología estandar para un sistema de accionamiento


Transformadores de accionamiento electrico (Drives)para ...

Chemical, Oil & Gas

Power Water

Marine

Pulp & Paper Special applications,e.g. wind tunnels

MetalsCement, Mining &Minerals


Aplicaciones típicas

Blowers & fansConveyorsCompressorsCrushers, rolling millsExtruders, mixersMarine propulsionMine hoistsPumpsRefinersGas & hydro turbinestartersSoft starters for largemachinesTest stands, wind tunnels

Transformadores en Presencia de ArmónicosNormas

IEC 61378-1 Converter transformers,Part 1 Transformers for IndustrialApplications

IEEE C57.18.10 IEEE standard Practicesfor Semiconductor Power RectifierTransformers”

IEC no hace requerimientos sobre nivelde aislamiento (BIL) IEEE si lo hace

Los diseños deben cubrirIncremento del esfuerzo dieléctrico en ellado del rectificador

Voltajes de modo común

Alto DU/dt

Corrientes armónicas

Compatibilidad electromagnética EMC

iu

-2000

-1500

-1000

-500

0

500

1000

1500

2000

0 5 10 15 20 25 30 35 40 45 50


Transformadores en Presencia de ArmónicosTransformador convertidor

Elevación de TemperaturaEl aumento de la temperatura con la corriente de cargareal, incluyendo las pérdidas debidas a los armónicos debeestar dentro de los límites especificados.

Existe margen en el aumento de la temperatura con lacorriente sinusoidal.

El diseño de los devanados debe ser capaz de soportartensiones mecánicas / térmicas debidas a la distribuciónde la temperatura más desigual que con corrientesinusoidal única ("efecto final").

Prueba de elevación de temperatura se puede hacer con lapotencia equivalente, o con un cálculo más detallado,basado en la norma IEC 61378



ACS 1000 – Input Transformer


ACS 1000 – Input Transformer

• 12-pulse or 24-pulse topology• Oil or dry type transformer

Conformity to IEC 61000-2-4 and IEEE 519/1992Total power factor: 0.95 constant over speed rangeTransformer can be placed inside the building or outdoor

Medium VoltageSupply Bus

Rectifier

I>> ProtMain Feeder

Breaker& Protection

12-pulseConverter Input

Transformer


Rectifier

I>> ProtMain Feeder

Breaker& Protection


Transformer


Rectifier

I>> ProtMain Feeder

Breaker& Protection


Transformer

12-pulse 24-pulse 24-pulse ACS 1000i


ACS 1000 Three- level Voltage Source Inverter (VSI)

Main Circuit Breaker, 12 pulse Transformer and Diode Rectifier stage

Fuseless Design, using Protection IGCTs

DC Link, DC Capacitors and Common Mode Choke (Option)

Three-level Voltage Source Inverter (VSI) equipped with IGCTsOutput sine wave filterACS 1000i: Air cooled drive with integrated transformer

Main CircuitBreaker

InputTransformer

PowerCables

MV ACInduction

Motor

MVSupply

Converter InputTransformer

I>> Prot

Main FeederBreaker

& Protection

ACS 1000 MV Variable Frequency Drive

Rectifier &Prot IGCTs

CommonMode Choke

Inverter OutputSine Filter

DC-Link

PowerCables

CommonMode Choke


One 5-winding transformer

Screen

A

B

P

D

C

ISN/2Uv0/2

ISN/2Uv0/2

ISN/2Uv0/2

ISN/2Uv0/2

Id/2

Id

Id/2

Udi0

I PN

U L

Two separate 3-winding transformer

D C

Id/2

Id

Id/2

Udi0

IPN

U L

ScreenAB

P1

ISN/2Uv0/2

ISN/2Uv0/2

ISN/2Uv0/2

ISN/2Uv0/2

P2Screen

ACS 1000 – 24-pulse input transformer

Technically a compromise(non-characteristic harmonics)

More compact and lower costs

Technically ideal and “save” solution

Large in size and expensive


ACS 1000 Transformer

3-winding transformer (12-pulse)

5-winding transformer (24-pulse)

2x3-winding transformers (2x12-pulse)

typical 3-winding construction

in the picture

IPN

Udi0

UL

Screen

I d

/2U v0/2U v0

A B

C

ISN ISN


Large 12 pulse rectifier transformer active part


ACS 6000 ”double ARU” with Pfisterer bushings


Double ARU transformer

Two active parts

in common tank


ACS 5000 Converter topology

Transformer

2 x 4-winding or 1 x 7-winding

Optional integrated dry type solution

36-pulse diode rectifier

3 x 12-pulse bridges

Input voltage: 1920 V / ±10%

DC link (in triplicate)

Three 5-level inverter unit

H-bridge configuration

Output voltage up to 6.9 kV

EMC-filter (dv/dt limitation at output) asstandard

Motor type

Asynchronous

Synchronous

Permanent magnet


One 7-winding transformer

-25

-5

-15

5

25

15

MCB

Inverter

Inverter

Inverter

One transformer :SR

Two separate 4-winding transformer

-20

20

0

-20

20

0

MCB

Transformer 1:SR/2

Inverter

Inverter

Inverter

Transformer 2:SR/2

ACS5000 - 36-pulse transformers

Technically a compromise, only for small powers(non-characteristic harmonics)More compact nut not always lowest costsPrimary currents must be measured separately

Technically ideal and “save” solution

Larger in size; compromise is to have two active parts in one oiltank

Oil transformers, two separate transformers are lowest costs

2 sets of CTs on primary side is required for overcurrentdetection (each primary side measured separately)


36-pulse diode rectifier

Constantly high power factor > 0.95 at any speed and load

Low network harmonics due to high pulse number

2x18p transformer or 1x36p transformerMain Power Supply Main Power Supply

ACS 5000 Network friendliness


Line to line voltage THD = 1.19%Scc = 500MVA, Xsc = 10%

Phase current TDD = 2.95%

ACS 5000 Network friendliness


ABB Special Transformers (PG SPT)Product Portfolio

Tailor made transformers and reactors (up to 63 MVA,170 kV)

railway transformersfurnace and rectifier transformersmarine & offshore transformersvariable speed drives transformersreactorsother special transformerstransformer service


Railway track side transformers

Railway transformersAutotransformers

Booster Transformers

Rectifier Transformers

Feeder Transformer

CustomersEPC’s, Railway companies


Furnace and Rectifier transformers

Furnace and Rectifiers transformersTransformers for Arc Furnaces

Transformers for Medium and HighCurrent Rectifiers

New installations or replacements

CustomersChemical and Metal Industry


Marine transformers

Oil type transformers for MarinePropulsion Transformers

Hotel Transformers

Magnetising Transformers

Environmental friendly applications, Midel

CustomersMarine Industry


Offshore transformers

Offshore transformersSubsea Transformers

Converter Transformers

OLTC Feeder Transformers

Converter Step Up Transformers

CustomersOil & Gas producers on offshore platforms,gas fields, FPSO vessels and movable units


VSD transformers

VSD transformersSupply Transformers for frequencyconverters

Step-up Transformers

CustomersMetals, Minerals and Mining Industry

Pulp and Paper, Water & Waste Water


Reactors

ReactorsCurrent limiting reactors

Neutral earthing reactors

Shunt reactors

Starting reactors

Earthing transformers

CustomersUtilities

Metal industry



Our experience in the Chilean market


SPT Focused Factory for LAM region

Strategic geographical location

Full current ABB Technologies implemented

More than 40 years of experience in transformers

Manufacturing culture based on operational excellence.

World class test failure rate.

ABB Pereira, ColombiaSpecial Transformer Manufacturer in SAM Region

Project name Teniente Nuevo Nivel Mina

Customer Codelco

Region SAM - Chile

Channel Minning

NM PPTR -

Product group SPT

Chilean MarketRegion Success story

New substation will be built into a “World Heritage”declared site (Sewell Mining Town)Codelco announced “high technology” will beimplemented.

Products

3 x SPT 115/34,5 kV – 30/40 MVA with Vegetable Oiland Nomex

ABB El mayor suministrador de Transformadores paraCentrales de Fuentes de Energía Renovable en Chile

Parques Eolicos Chile:

520 MW

Base instalada ABB

Totoral (2 x 50 MW)

Negrete Cuel (40 MW)

Valle de los Vientos (100 MW)

El Arrayan (130 MW)

TOTAL ABB 370 MW


Skanska – SN Power – ParqueEólico Totoral . ABB Colombia

PARQUE EOLICONEGRETE CUEL

Primer Transformador de Poder en Chile conTecnologia de devanados en Aluminio.

Alcance: 30/40 MVA, 154/23 kV con OLTC en AT

Cliente: Mainstream Renewable Power Chile

Alcance: 2 Trx 50/65 MVA, 110/23 kV con OLTCen AT

Cliente: ENEL Green Power Chile


PARQUE EOLICO VALLE DELOS VIENTOS

Hernan Escarria. PTI – Santiago de Chile, Junio 2013 Small ... · © ABB Group June 3, 2013 |...

Documents

Transcript of Hernan Escarria. PTI – Santiago de Chile, Junio 2013 Small ... · © ABB Group June 3, 2013 |...